As electric vehicles (EVs) and renewable energy systems become cornerstones of the modern energy economy, battery manufacturing — and recycling — are more important than ever. But what happens when those batteries reach the end of their life?
For manufacturers, reclaiming rare earth materials (REEs) used in drive motors and other non-REE raw materials used in lithium-ion batteries, the challenges go far beyond dismantling. It’s the handling of combustible powder ingredients that determines whether your process is safe and scalable.
At AZO, we help battery recyclers transition from black mass to reusable, high-purity powders through precision-engineered solutions designed for every stage of powder processing. Here are the challenges we see in the battery manufacturing industry and how to overcome them.
Lithium and cobalt are essential to modern energy storage, but they’re geographically constrained and expensive to mine. With much of the global supply originating in China or other limited regions, battery recycling helps U.S. manufacturers secure necessary inputs without becoming susceptible to shifting tariffs or trade routes.
The good news: when these elements are reclaimed, they don’t lose their functionality: the material’s integrity is maintained. A recycled lithium or cobalt particle can perform just as well as new material in a battery cell, making the reclaiming process both economically and environmentally smart.
But getting to that reusable state is complex, especially when handling reactive powders.
Before any material can be reused, spent lithium-ion batteries must be crushed to separate out the valuable materials. This step poses one of the biggest safety risks in the process.
When lithium-ion batteries are compressed, the combination of heat, oxygen, and chemical reaction can cause spontaneous ignition. Some crushing equipment creates enough energy to trigger combustion, especially in an oxygen-rich environment.
This is an enormous safety hazard for workers, as the battery fire also releases toxic gases. Trying to put the fire out with water is a no-go — it will only make it worse. You need special Class D fire extinguishers.
AZO’s advice: Invest in a crushing environment that uses nitrogen inerting. By removing oxygen from the equation, you eliminate one leg of the fire triangle and significantly reduce the risk of thermal runaway.
After crushing, the resulting “black mass” still contains electrolyte liquid, a necessary component for charging the battery but a volatile one during processing.
To meet EPA regulations, this liquid cannot be released into the atmosphere. It must be carefully removed before further handling.
AZO offers a solution: The AMIXON® mixer dryer reactor. This equipment dries out electrolytes under controlled conditions — a vital step in preparing powders for classification and reuse. While the investment in this technology can range into the six- or seven-figure territory, it’s a worthwhile step for safe, compliant operation.
Once batteries are broken down, AZO helps manufacturers make sense of the chaos so often linked to powder handling. Here’s what a streamlined battery powder reclamation process can look like:
The industry isn’t stopping at lithium-ion. New chemistries like solid-state batteries and iron-air are reshaping how we think about energy storage.
These next-gen formats offer:
But they also introduce new challenges, especially around powder purity and flowability.
At AZO, we’re adapting alongside this shift. Our New Energy division collaborates with clients working on energy storage systems for large-scale wind and solar applications. From bulk bag unloaders to gain-in-weight batching systems and pneumatic conveying, we’re supporting these innovators with tailored powder handling systems that meet changing specifications.
AZO isn’t in the business of battery destruction, but once you’ve processed your packs down to powders, we bring order, accuracy, and safety to the material recovery phase.
Our systems are engineered to:
If you’re navigating the complexities of battery powder recovery, or beginning to explore solid-state battery production, bring us in early. Our team will help evaluate your material behavior, identify risk points, and design a system that meets your performance targets and compliance requirements.
Battery recycling isn’t just about sustainability. It’s about strategic independence, safer operations, and long-term cost savings. AZO’s role is to make the powder management part of the process as efficient, clean, and safe as possible.
Planning a facility build or retrofit? Talk to an AZO expert.